Oxygen concentrator apparatus and method with an oxygen assisted venting system

ABSTRACT

An oxygen concentrator may rely on a pressure swing adsorption process to produce an oxygen enriched gas stream from canisters filled with granules capable of separation of oxygen from an air stream. The adsorption process uses a cyclical pressurization and venting of the canisters to generate an oxygen enriched gas stream. During venting of the canisters, use of oxygen as a purge gas may improve the efficiency and lifetime of the oxygen concentrator.

PRIORITY

This application is a Continuation of U.S. patent application Ser. No.12/163,549 entitled “OXYGEN CONCENTRATOR APPARATUS AND METHOD”, filed onJun. 27, 2008, which claims the benefit of priority of U.S. ProvisionalPatent Application Ser. No. 60/970,371 titled “Oxygen ConcentratorApparatus and Method”, filed on Sep. 6, 2007, both of which are herebyincorporated by reference in its entirety as though fully and completelyset forth herein.

BACKGROUND

1. Field of the Invention

The present invention relates generally to health equipment and, morespecifically, to oxygen concentrators.

2. Description of the Related Art

Patients (e.g., those suffering with diseases such as emphysema,congestive heart failure, acute or chronic pulmonary insufficiency,etc.) may require supplemental oxygen. Other people (e.g., obeseindividuals) may also require supplemental oxygen, for example, tomaintain elevated activity levels. Doctors may prescribe oxygenconcentrators or portable tanks of medical oxygen for these patients.Usually a specific oxygen flow rate is prescribed (e.g., 1 liter perminute (LPM), 2 LPM, 3 LPM, etc.) Oxygen concentrators used to providethese flow rates may be bulky and heavy making ordinary ambulatoryactivities with them difficult and impractical. Portable tanks ofmedical oxygen may also be heavy and contain limited amounts of oxygen.

Oxygen concentrators may take advantage of pressure swing absorption.Pressure swing absorption may involve using a compressor to increase airpressure inside a canister that contains granules of a micro-porousmineral. As the pressure increases, certain air molecules may becomesmaller and may be absorbed into the micro-pores of the granules. Anexample of such a granule is found in certain volcanic ash. Syntheticgranules (e.g., zeolite) may also be available in various granule andpore sizes. These granules may thus be used to separate gases ofdifferent molecular size (e.g., zeolite may be used to separate nitrogenand oxygen). Ambient air usually includes approximately 78% nitrogen and21% oxygen with the balance comprised of argon, carbon dioxide, watervapor and other trace elements. When pressurized air is applied to thegranules, nitrogen in the air may be absorbed in the micro-pores of thegranules because of the smaller size of the nitrogen molecule. As thegranules are saturated, the remaining oxygen may be allowed to flowthrough the canister and into a holding tank. The pressure in thecanister may then be vented from the canister resulting in thepreviously absorbed nitrogen being released from the pores in thegranules. A small portion of the bled oxygen may be used to furtherpurge the nitrogen from the canister. The process may then be repeatedusing additional ambient air. By alternating canisters in a two-canistersystem, one canister can be collecting oxygen while the other canisteris being purged (resulting in a continuous separation of the oxygen fromthe nitrogen). In this manner, oxygen can be accumulated out of the airfor a variety of uses include providing supplemental oxygen to patients.

Prior art oxygen concentrators may have several limitations. Forexample, the compressor on the oxygen concentrator may be operated at alevel required to meet the demands of the user regardless of thebreathing rate of the user. In addition, the length of the supply tubingto the nasal cannula or mask from the oxygen concentrator may be limitedto 6 to 8 feet. This limitation may be a problem for users using thedevice in their sleep. Prior art oxygen concentrators may also include alimited sensor and alarm to notify a user if the oxygen supplied by theoxygen concentrator is too low. Currently oxygen sensors in oxygenconcentrators use a heated filament as a component. In addition, time,pressure and orifice size are used to determine a volume of airdelivered to a user of an oxygen concentrator (however, this measurementtechnique may not account for pressure fluctuations).

SUMMARY

In various embodiments, an oxygen concentrator for concentrating oxygenmay include canisters (e.g., to hold zeolite) integrated into a moldedbody. The oxygen concentrator may be made of one or more plastic moldedparts (i.e., housing components) and may further include valves, flowrestrictors (e.g., press fit flow restrictors), air pathways, and othercomponents coupled to or integrated into the one or more housingcomponents. In some embodiments, the canisters may be injection molded(e.g., using plastic). The injection molded housing components mayinclude air pathways for air flowing to and from the canisters. In someembodiments, valves may be coupled to the one or more housing componentsto direct air through the air pathways. In some embodiments, one or morecompressors (e.g., a dual-pump diaphragm compressor) may compress airthrough the canisters. Zeolite (or another granule) in the canisters mayseparate nitrogen and oxygen in the air as the air is compressed throughthe canisters. Some of the separated oxygen may also be used to ventnitrogen from the canisters. In some embodiments, a spring baffle may beused to bias the granules in the canister to avoid damage to thegranules when the oxygen concentrator is moved. The spring baffle may bea single molded part (e.g., injection molded part). In some embodiments,the oxygen concentrator may include two-step actuation valves. Two stepactuation valve may be operable to be opened by application of a firstvoltage and further operable to be held open by a second voltage (thesecond voltage may be less than the first voltage to conserve energy).In some embodiments, a solar panel may be coupled to a battery of theoxygen concentrator to charge the battery using solar energy.

In some embodiments, a pressure transducer coupled to the oxygenconcentrator may detect a change in pressure corresponding to a start ofa user's breath. A processor coupled to the pressure transducer mayexecute program instructions to implement a first mode in which asensitivity of the pressure transducer is attenuated. In a second mode,the sensitivity of the pressure transducer may not be attenuated. Forexample, the sensitivity of the pressure transducer may be attenuated inwindy environments or while the user is active. The sensitivity may notbe attenuated, for example, while the user is asleep or otherwisesedentary.

In various embodiments, the pressure transducer, coupled to the oxygenconcentrator, may be used to detect a breathing rate of the user of theoxygen concentrator. The processor coupled to the pressure transducermay execute program instructions to adjust power to the one or morecompressors based on the breathing rate of the user of the oxygenconcentrator. In some embodiments, the compressors may switch between afirst phase of operation in which only a subset of the compressorsoperate and a second phase of operation in which additional compressors(e.g., all available compressors) operate. For example, fewercompressors may be used during lower user breathing rates.

In some embodiments, the oxygen concentrator may use a dual lumen(including a first tube and a second tube). The first tube may be usedto deliver oxygen to the user's nose and the second tube may extend tothe entrance of the user's nose to communicate a change in pressure(e.g., from the start of a breath through the user's nose) from theentry of the user's nose to the oxygen concentrator. In someembodiments, the second tube may have a smaller radius than the firsttube to allow for increased sensitivity to pressure changes in thesecond tube.

In some embodiments, a transducer may be coupled to the prongs of thenasal cannula to detect a change in pressure resulting from a start of abreath taken by the user. In some embodiments, a Hall-effect sensor maybe used at the nasal cannula or at the oxygen concentrator to detect airmovement (e.g., due to a user's breath). The Hall-effect sensor may usea magnet coupled to a vane (inserted into the nasal cannula) to detectmovement of air in the nasal cannula.

In some embodiments, an ultrasonic sensor may be used to detect thepresence of a gas (e.g., to detect the concentration of oxygen in airdelivered to a user). In some embodiments, the ultrasonic sensor may beplaced on a chamber of the oxygen concentrator that receives air to bedelivered to the user. An ultrasonic emitter of the ultrasonic sensormay provide an ultrasonic sound wave through the chamber and anultrasonic receiver may detect the ultrasonic sound wave that hastraveled through the air of the chamber. A processor coupled to theultrasonic emitter and the ultrasonic receiver may execute programinstructions to determine a speed of the sound wave through the chamber(the speed of the sound wave may indicate a relative concentration of aconstituent of the gas (e.g., the concentration of oxygen)).

In some embodiments, an audio device (e.g., an MP3 (Moving PictureExperts Group Layer-3 Audio) player, mobile phone, etc.) may beintegrated into the oxygen concentrator (e.g., integrated into an outerhousing of the oxygen concentrator). A microphone and headphone may becoupled to the audio device through a wire or may be wirelesslyconnected. In some embodiments, the microphone may be coupled to a nasalcannula or other oxygen delivery mechanism coupled to the oxygenconcentrator. Other configurations are also contemplated. Theheadset/microphone combination may also be used with the oxygenconcentrator for hands-free cellular phone use. Other uses are alsocontemplated.

In some embodiments, various components of the oxygen concentrator maybe arranged in one or more housings (e.g., a foam housing inside of alight-weight plastic enclosure). In some embodiments, the foam housingmay include passages for air flow and/or electrical connections betweencomponents of the oxygen concentrator. Other configurations are alsocontemplated. In some embodiments, additional housings may be used.

BRIEF DESCRIPTION OF THE DRAWINGS

A better understanding of the present invention may be obtained when thefollowing detailed description is considered in conjunction with thefollowing drawings, in which:

FIGS. 1 a-b illustrate two molded oxygen concentrator housingcomponents, according to an embodiment.

FIGS. 2 a-b illustrates the second housing component of the oxygenconcentrator, according to an embodiment.

FIG. 3 illustrates a diagram of the components of the oxygenconcentrator, according to an embodiment.

FIG. 4 illustrates a vented lid for the oxygen concentrator, accordingto an embodiment.

FIGS. 5 a-h illustrate various views of the first housing component ofthe oxygen concentrator, according to an embodiment.

FIGS. 6 a-h illustrate additional views of the internal structure of thefirst housing component of the oxygen concentrator, according to anembodiment.

FIG. 7 illustrates a spring baffle, according to an embodiment.

FIG. 8 illustrates a butterfly valve seat, according to an embodiment.

FIGS. 9 a-f illustrate different hose/pressure transducerconfigurations, according to an embodiment.

FIG. 10 illustrates a hall effect pressure transducer and associatedhose configuration, according to an embodiment.

FIG. 11 illustrates a circuit diagram of an ultrasonic sensor assembly,according to an embodiment.

FIG. 12 illustrates a shifted wave pulse as detected by the ultrasonicsensor assembly, according to an embodiment.

FIG. 13 illustrates the components of the shift for the oxygenconcentrator, according to an embodiment.

FIG. 14 illustrates various gates for the ultrasonic sensor, accordingto an embodiment.

FIG. 15 illustrates a solar panel coupled to the oxygen concentrator,according to an embodiment.

FIG. 16 illustrates a flowchart of an embodiment for oxygen concentratoroperation, according to an embodiment.

FIG. 17 illustrates a flowchart of an embodiment for oxygen concentratorassembly, according to an embodiment.

FIG. 18 illustrates a flowchart of an embodiment for compressor control,according to an embodiment.

FIG. 19 illustrates a flowchart of an embodiment for ultrasonic sensoroperation, according to an embodiment.

FIG. 20 illustrates a headset/microphone boom, according to anembodiment.

FIGS. 21 a-c illustrate outer housings, according to two embodiments.

FIG. 22 illustrates an embodiment of an enclosure housing.

FIG. 23 illustrates an embodiment of two half sections of the enclosurehousing.

FIG. 24 illustrates an embodiment of a first foam housing.

FIG. 25 illustrates an embodiment of a complimentary second foamhousing.

FIG. 26 illustrates a side and front profile of a component arrangementin the foam housings, according to an embodiment.

FIG. 27 illustrates three embodiments of gas mixture delivery profilesfor the oxygen concentrator.

FIGS. 28 a-d illustrate an attachable external battery pack for theoxygen concentrator, according to an embodiment.

While the invention is susceptible to various modifications andalternative forms, specific embodiments thereof are shown by way ofexample in the drawings and will herein be described in detail. Itshould be understood, however, that the drawings and detaileddescription thereto are not intended to limit the invention to theparticular form disclosed, but on the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the present invention as defined by the appendedclaims. Note, the headings are for organizational purposes only and arenot meant to be used to limit or interpret the description or claims.Furthermore, note that the word “may” is used throughout thisapplication in a permissive sense (i.e., having the potential to, beingable to), not a mandatory sense (i.e., must). The term “include”, andderivations thereof, mean “including, but not limited to”. The term“coupled” means “directly or indirectly connected”.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIGS. 1 a-2 b illustrate various views of housing components 111 a-b foran oxygen concentrator 100, according to an embodiment. In someembodiments, the oxygen concentrator 100 may concentrate oxygen out ofthe air to provide supplemental oxygen to a user. The oxygen may becollected from ambient air by pressurizing the ambient air in a canister(e.g., canisters 101 a-b) with granules 139 (e.g., molecular sievegranules) such as zeolite 391 (see FIG. 3). Other materials (usedinstead of or in addition to zeolite 391) may be used. In someembodiments, the air may be pressurized in the canister 101 using one ormore compressors 301. In some embodiments, the ambient air may bepressurized in the canisters 101 to a pressure approximately in a rangeof 13-20 pounds per square inch (psi). Other pressures may also be used(e.g., if a different granule type is used). Under pressure, thenitrogen molecules in the pressurized ambient air may enter the pores ofthe granules 139 in the canister 101 which may hold the nitrogenmolecules as oxygen molecules flow through the canister 101 and out of arespective exit aperture 601 (see FIG. 6). While examples providedherein describe separating nitrogen and oxygen, it is to be understoodthat other embodiments may include separating other atom/moleculestypes. In some embodiments, the oxygen molecules leaving aperture 601may be collected in an oxygen accumulator 103 prior to being provided toa user through outlet 107. In some embodiments, a tube (e.g., tube 907in FIGS. 9 a-b) may be coupled to the outlet 107 to deliver the oxygento the user through a nasal cannula 903. In some embodiments, tube 907may be coupled to an exit nozzle 2111 a,b (see FIGS. 21 a-b) that iscoupled to outlet 107 through a silicone rubber tube 197 (othermaterials for the tube 197 are also contemplated). Other deliverymechanisms and routes are also contemplated. For example, the outlet mayinclude a tube that directs the oxygen toward a user's nose and/or mouththat may not be directly coupled to the user's nose. In someembodiments, the oxygen provided to the user may be of 90 percent orgreater purity (e.g., 97 percent purity). Other oxygen concentrationsare also contemplated (e.g., lower purity levels may be desired).

In some embodiments, after applying the initial pressurized air to acanister 101 (e.g., canister 101 a), the pressure in the canister 101may be released, and the nitrogen molecules in the canister 101 may beexpelled from the oxygen concentrator 100 (e.g., through respectivevalve 305 c or 305 d and then through muffled vent 327). Other exitmechanisms may also be used. In some embodiments, the canister 101 maybe further purged of nitrogen using concentrated oxygen that isintroduced into the canister 101 through respective aperture 601 (e.g.,from oxygen being concentrated from the other canister 101). In someembodiments, the oxygen concentrator 100 may include two or morecanisters 101. For example, while canister 101 a is being purged ofnitrogen, canister 101 b may be collecting oxygen. Other configurationsare also contemplated (e.g., one canister, four canisters, etc.).

In some embodiments, pressurized air from the compressors 301 may enterair inlets 109 a-b and then may be directed using various valves 305(attached to valve seats 105) and internal air pathways. As shown inFIGS. 1 a-3, valve seats 105 a-g may correspond to respective valves 305a-g (e.g., valve 305 a is seated in valve seat 105 a, etc.). As seen inthe example valve 305 in FIG. 2 a, valves 305 may include high pressurestems (e.g., stem 211 a) and low pressure stems (e.g., stem 211 b). Thevalves 305 may also include gaskets around the stems (e.g., gasket 209).The valves 305 may be actuated/powered through electrical connection213. In some embodiments, the valves 305 may be coupled to andcontrolled by processor 399. The valves 305 may be coupled to theirrespective valve seats 105 (e.g., through size 256 screws 299 throughslots 215 on either side of the valve 305 and into their respectivefastening apertures (e.g., screw apertures 135 a,b)). The valves 305 mayalso be coupled to the valve seats 105 through other techniques (e.g.,using adhesive, rivets, etc.). Other valve and valve seat configurationsare also contemplated.

In some embodiments, air may be pulled into the oxygen concentrator 100through compressors 301 a-b (which may be dual-pump diaphragmcompressors). In some embodiments, air may flow into the air inlets 109a-b from compressors 301 a-b (e.g., one inlet per respectivecompressor). In some embodiments, one of valves 305 a or 305 b may beclosed (e.g., as signaled by processor 399) resulting in the combinedoutput of both compressors 301 flowing through the other respectivevalve seat 105/valve 305 into a respective canister 101 (e.g., eithercanister 101 a or canister 101 b). For example, if valve 305 b (seatedin valve seat 105 b) is closed, the air from both compressors 301 mayflow through valve 305 a (seated in valve seat 105 a). If valve 305 a isclosed, the air from both compressors 301 may flow through valve 305 b.In some embodiments, valve 305 a and valve 305 b may alternate toalternately direct the air from the compressors 301 into respectivecanisters 101 a or 101 b. In some embodiments, if one of the twocompressors 301 fails, the working compressor's output may bealternately directed between canisters 101 a,b. This may allow theoxygen concentrator 100 to at least partially work (e.g., on halfoutput) until the user can arrange another oxygen source.

In some embodiments, as air flows through respective canister 101 a or101 b, oxygen may pass through the granules 139 in the canister 101while the nitrogen is retained in the granules 139. As seen in FIG. 6G,the oxygen may pass through opening 601 a at the end of canister 101 a,through side tube 121 a, through check valve 123 a, and into oxygenaccumulator 103. Alternately, the oxygen may pass through opening 601 bat the end of canister 101 b, through side tube 121 b, through checkvalve 123 b, and into oxygen accumulator 103. From oxygen accumulator103, the air may flow through valve 305 g (which may be a high pressureF-valve) seated in valve seat 105 g. In some embodiments, the air mayflow through a flow restrictor 311 (e.g., a 0.025 R flow restrictor).Other flow restrictor types and sizes are also contemplated. In someembodiments, a separate restrictor may not be used (e.g., the diameterof the air pathway in the housing may be restricted). The air may thenflow through an oxygen sensor (e.g., ultrasonic sensor 307 comprised ofan ultrasonic emitter 201 and receiver 203), a filter 385 (e.g., tofilter bacteria, dust, granule particles, etc), through silicone rubbertube 197, and then out of the oxygen concentrator 100 and to the user(e.g., through a tube 907 and nasal cannula 903 coupled to outlet 107).

In some embodiments, ultrasonic emitter 201 may include multipleultrasonic emitters (e.g., emitters 201 a,b) and ultrasonic receiver 203may include multiple ultrasonic receivers (e.g., receivers 203 a,b). Insome embodiments, the multiple ultrasonic emitters and multipleultrasonic receivers may be axially aligned (e.g., across the gasmixture flow path which may be perpendicular to the axial alignment).Other emitter/receiver configurations are also contemplated. In someembodiments, the ultrasonic sensor 307 and, for example, a gas flowmeter 1143 (as seen in FIG. 11) may provide a measurement of flowdelivery (or actual amount of oxygen being delivered). For example, thegas flow meter 1143 may use the Doppler effect to measure a volume ofgas provided and the ultrasonic sensor 307 may provide the concentrationof oxygen of the gas provided. These two measurements together may beused by the processor to determine an approximation of the actual amountof oxygen provided to the user. Other sensors may also be used in flowdelivery measurement.

In some embodiments, valve 305 a may be closed and valve 305 c (seatedin valve seat 105 c) may be opened to direct nitrogen (under pressure)out of canister 101 a and through the muffled vent out 327. Similarly,valve 305 b may be closed and valve 305 d (seated in valve seat 105 d)may be opened to direct nitrogen (under pressure) out of canister 101 band through the muffled vent out 327.

In some embodiments, a portion of the collected oxygen may betransferred from one canister 101 (e.g., the canister 101 currentlyproducing oxygen) to the back of the other canister 101 (e.g., thecanister 101 currently venting nitrogen) in order to further purge thenitrogen. The oxygen may travel through flow restrictors 321, 323, and325 between the two canisters 101.

Flow restrictor 321 may be a trickle flow restrictor. Flow restrictor321 may be a 0.011 R flow restrictor (e.g., with a radius 0.011*theradius of the tube it is inside) and flow restrictor 323 and flowrestrictor 325 may be a 0.013 R flow restrictors. Other flow restrictortypes and sizes are also contemplated. For example, flow restrictor 321may be a 0.009 R flow restrictor. In some embodiments, the flowrestrictors may be press fit flow restrictors that restrict air flow byintroducing a narrower radius in their respective tube. In someembodiments, the press fit flow restrictors may be made of sapphire,metal or plastic (other materials are also contemplated).

Valve 305 e and valve 305 f may be opened to direct oxygen from theproducing canister 101 to the venting canister 101. The valves may beopened for a short duration during the venting process (and may beclosed otherwise) to prevent excessive oxygen loss out of the purgingcanister 101. Other durations are also contemplated. The pair ofequalization/vent valves 305 e,f may work with flow restrictors 323 and325 to optimize the air flow balance between the two canisters 101 a,b.This may allow for better flow control for venting the canisters 101 a,bwith oxygen from the other of canisters 101 a,b. It may also providebetter flow direction between the two canisters 101 a,b. For example,when directing oxygen from canister 101 b to canister 101 a to vent thenitrogen out of canister 101 a, oxygen may flow through flow restrictor323 and then open valve 305 f on a first air pathway, and through openvalve 305 e and then flow restrictor 325 on the second air pathway (oneair pathway ideal and one air pathway less ideal). Similarly, whendirecting oxygen from canister 101 a to canister 101 b to vent thenitrogen out of canister 101 b, oxygen may flow through open valve 305 fand then flow restrictor 323 on one air pathway and through flowrestrictor 325 then open valve 305 e on the second air pathway (one airpathway ideal and one air pathway less ideal). Therefore, a similarvolume of oxygen may be used from each canister 101 when purging theother canister 101. The opposite arrangement of the valve and flowrestrictor on parallel air pathways may equalize the flow pattern of theoxygen between the two canisters 101. If not equalized, more oxygen maybe used in venting one of the canisters 101 than the other of thecanisters 101 (resulting in less oxygen available to the user on everyother cycle). Equalizing the flow may allow for a steady amount ofoxygen available to the user over multiple cycles and also may allow apredictable volume of oxygen to purge the other of the canisters 101.Other numbers of valves and/or flow resistors are also contemplated.Other arrangements are also contemplated. For example, one air pathwaymay be provided with a balanced flow pattern in either direction. Insome embodiments, the air pathway may include a first flow restrictor, avalve, and a second flow restrictor (of similar size as the first flowrestrictor) such that when the valve is open, air flows through therestrictors and valve in a similar pattern (restrictor, valve,restrictor) regardless of direction. In some embodiments, the airpathway may not have restrictors but may instead have a valve with abuilt in resistance (or the air pathway itself may have a narrow radiusto provide resistance) such that air flow through the valve has the sameresistance regardless of direction through the valve.

Air being vented out of the canisters 101 may travel through canisterexit aperture 297 a or 297 b, through respective valve 305 c or 305 d,through the muffled vent out 137, and then through the vent 401 (e.g.,see FIG. 4). The muffled vent out 137 may include open cell foam (oranother material) between the nitrogen exit aperture 217 a of thehousing component 111 a and the vent 401 to muffle the air leaving theoxygen concentrator 100. Other muffling techniques are alsocontemplated. In some embodiments, the combined mufflingcomponents/techniques may provide for oxygen concentrator operation at asound level below 50 decibels. The oxygen concentrator may also operateat lower or higher sound levels. In some embodiments, the vent 401 mayinclude apertures 403 that may be smaller in cross section than the opencell foam in the muffled vent out 137. This may allow air to exit whilekeeping the open cell foam in the muffled vent out 137. In someembodiments, the vent 401 may be made of a molded plastic (e.g.,injection molded). Other materials are also contemplated. In someembodiments, the vent 401 may be coupled to the muffled vent out 137 ofhousing component 111 a through an adhesive or solvent weld. Othercoupling techniques are also contemplated (e.g., the vent 401 may snapin place).

In some embodiments, the valves 305 may be silicon plunger solenoidvalves (other valves are also contemplated). Plunger valves may be quietand have low slippage. In some embodiments, a two-step valve actuationvoltage may be used to control the valves 305. For example, 24 volts (V)may be applied to the valve to open the valve 305, and then the voltagemay be reduced to 7 V to keep the valve 305 open. In some embodiments,the voltages and the duration of the voltages may be controlled byprocessor 399. The valves 305 may require more voltage to overcomestatic friction, but once open, less voltage may be required to keep thevalve 305 open (the sliding friction may be less than the staticfriction on the valve 305). Using less voltage to keep the valve 305open may use less power (Power=Voltage*Current). Lower powerrequirements may lead to a longer battery life. In some embodiments, thevoltage may be applied as a function of time that is not necessarily astepped response (e.g., a curved downward voltage between an initial 24V and 7 V). Other response patterns are also contemplated. Othervoltages are also contemplated (e.g., voltages larger or smaller than24V, 7V). For example, different voltages may be used for differentvalves.

In some embodiments, the housing for the oxygen concentrator 100 mayinclude two housing components 111 a-b. The housing components 111 a-bmay be formed separately and then coupled together (other numbers ofhousing components are also contemplated). In some embodiments, thehousing components 111 a-b may be injection molded (e.g., from aninjection die molded plastic). Other manufacturing techniques are alsocontemplated (e.g., compression molding). The housing components 111 a-bmay be made of a thermoplastic such as polycarbonate, methylene carbide,polystyrene, acrylonitrile butadiene styrene (ABS), polypropylene,polyethylene, or polyvinyl chloride. Other materials are alsocontemplated (e.g., the housing components 111 a-b may be made of athermoset plastic or metal (such as stainless steel or a light-weightaluminum alloy)). Lightweight materials may be used to reduce the weightof the oxygen concentrator 100. In some embodiments, the two housings111 a and 111 b may be fastened together using screws or bolts. Forexample, screws may be placed through apertures 131 a-g (e.g., one screwthrough aperture 131 a and 131 e, etc.). Other fastening techniques arealso contemplated (e.g., rivets). As another example, the housingcomponents 111 a,b may be solvent welded together.

As shown, valve seats 105 a-f and air pathways may be integrated intothe housing components 111 a-b to reduce a number of seal connectionsneeded throughout the air flow of the oxygen concentrator 100 (this mayreduce leaks and potential failure points). In various embodiments, thehousing components 111 a-b of the oxygen concentrator 100 may form atwo-part molded plastic frame that includes, for example, two canisters101 coupled to two compressors and an air delivery mechanism throughmultiple air pathways and valve seats 105 a-f integrated into the frame.In some embodiments, the oxygen concentrator 100 may be formed out of adifferent number of molded components (e.g., one unitary component orusing three or more components). Other techniques for forming the oxygenconcentrator are also contemplated (e.g., laser sintering, machining,etc.).

In some embodiments, air pathways/tubing between different sections inthe housing components 111 a,b (e.g., between the canisters 101 a,b andthe oxygen accumulator 103) may take the form of molded channels. Thetubing in the form of molded channels for air pathways may occupymultiple planes in the housing components 111 a,b (e.g., may be formedat different depths and at different x,y,z positions in the housingcomponents 111 a,b). In some embodiments, a majority or substantiallyall of the tubing may be integrated into the molded housing (e.g.,housing components 111 a,b) to reduce potential leak points.

In some embodiments, prior to coupling the housing components 111 a,btogether, O-rings may be placed between various points of the housingcomponents 111 a,b (e.g., O-rings 135 a,b between housing components 111a and 111 b at tubes 121 a,b). O-rings may also be placed between theends of canisters 101 a,b and the housing component 111 b (which mayfunction as a manifold) and between the end of the oxygen accumulator103 and the housing component 111 b. Other O-rings are alsocontemplated. In some embodiments, filters 207 a,b may also be fastened(e.g., welded or using an adhesive) to the inside of the housingcomponent 111 a and/or 111 b to prevent granules 139 from getting intothe tubing/valves coupled to the canisters 101 a,b. The filters 207 mayalso be welded onto either side of the spring baffles 701 to keep thegranules 139 out of the tubing, etc. of housing component 111 b. Forexample, the filter 207 may be welded onto the non-spring side of thespring baffle 701. The filters 207 may be spunbond filters made of oneor more layers of textile cloth. Other filters are also contemplated. Insome embodiments, the granules 139 may be added prior to coupling thehousing components 111 a,b together.

In some embodiments, components may be integrated and/or coupledseparately to the housing components 111 a-b. For example, tubing, flowrestrictors (e.g., press fit flow restrictors), oxygen sensors (e.g.,comprising an emitter 201 and receiver 203), granules 139 (e.g.,zeolite), check valves 123, plugs, processors and other circuitry,battery 395, etc. may be coupled to the housing components 111 a-bbefore and/or after the housing components 111 a-b are coupled together.As disclosed, the oxygen concentrator 100 and components together mayweigh less than 5 pounds and be smaller than 200 cubic inches. Otherdimensions are also contemplated.

In some embodiments, apertures leading to the exterior of the housingcomponents 111 a-b may be used to insert devices such as flowrestrictors. Apertures may also be used for increased moldability. Oneor more of the apertures may be plugged after molding (e.g., with aplastic plug). Plugs such as plug 125 a and 125 b may be used to plugapertures formed in housing component 111 to facilitate the injectionmolding process. In some embodiments, flow restrictors may be insertedinto passages prior to inserting plug to seal the passage. For example,as seen in FIG. 6 g, flow restrictor 321 may be a press-fit flowrestrictor that is inserted into aperture 603 a followed by a plug 127a. Flow restrictor 323 may be inserted into aperture 603 b followed byplug 127 b. Flow restrictor 325 may be inserted into aperture 603 efollowed by plug 127 e. Other plugs may also be used (e.g., plug 127 c(for aperture 603 c), plug 127 d (for aperture 603 d), plug 127 f (foraperture 603 f), and plug 127 g (for aperture 603 g)). Press fit flowrestrictors may have diameters that may allow a friction fit between thepress fit flow restrictors and their respective apertures. In someembodiments, an adhesive may be added to the exterior of the press fitflow restrictors to hold the press fit flow restrictors in place onceinserted. In some embodiments, the plugs may have a friction fit withtheir respective tubes (or may have an adhesive applied to their outersurface). The press fit flow restrictors and/or other components may beinserted and pressed into their respective apertures using a narrow tiptool or rod (e.g., with a diameter less than the diameter of therespective aperture). Other insertion mechanisms are also contemplated.In some embodiments, the press fit flow restrictors may be inserted intotheir respective tubes until they abut a feature in the tube to halttheir insertion. For example, the feature may include a reduction inradius (e.g., see reduction 605 in FIG. 6G). Other features are alsocontemplated (e.g., a bump in the side of the tubing, threads, etc.). Insome embodiments, press fit flow restrictors may be molded into thehousing components 111 a,b (e.g., as narrow tube segments).

In some embodiments, spring baffle 129 may be placed into respectivecanister receiving portions of the housing component 111 b with thespring side of the baffle 129 facing the exit of the canister 101. Insome embodiments, the spider legs 701 of the spring baffle 129 mayengage the ridges 133 on the back of the canisters 101. FIG. 7 alsoillustrates an embodiment of the spring baffle 129. The spring baffle129 may apply force to granules 139 in the canister 101 while alsoassisting in preventing granules 139 from entering the exit apertures601 a,b. The spring baffle 129 may keep the granules 139 compact whilealso allowing for expansion (e.g., thermal expansion). For example,during thermal expansion (or, for example, during a physical shock),spider legs 701 may compress. Keeping the granules 139 compact mayprevent the granules 139 from breaking (e.g., during movement of theoxygen concentrator 100). The spring baffle 129 may be made of one piecemolded plastic. Other materials and manufacturing techniques are alsocontemplated (e.g., stainless steel).

In some embodiments, check valves 123 may prevent oxygen from tube 121 aor the oxygen accumulator 103 from entering tube 121 b and may preventoxygen from tube 121 b and the oxygen accumulator 103 from entering tube121 a. In some embodiments, a butterfly check valve 123 may be used(other check valve types are also contemplated). FIG. 8 illustrates anembodiment of a butterfly check valve 123 (e.g., see butterfly valves123 a,b in FIG. 1) with a butterfly component 801. In some embodiments,the butterfly component 801 may be pulled into the valve seat 813 untilthe ball 803 of the butterfly component 801 snaps through the aperture805 to hold the butterfly component 801 in place. As air flows indirection 807 through the check valve 123, (e.g., through apertures 811a-d) the butterfly component 801 may bend to allow air through the valve123 (see configuration 809). If air tries to flow in the oppositedirection (or if air flow is at rest), the butterfly component 801 maytake configuration 813 to prevent air flow through the check valve 123.

In some embodiments, one or more compressors (e.g., two compressors 301a,b) may provide compressed air in a parallel arrangement. In someembodiments, dual-pump diaphragm compressors may be used for longer life(e.g., >20000 operating hours). Dual-pump diaphragm compressors may alsowork without needing additional oil. Dual-pump diaphragm compressors mayalso require less volume than larger single compressors used to compressa similar amount of air. Other compressors may also be used (e.g., a twostage compressor may be used).

In some embodiments, both compressors 301 a,b may be used during normaloperation (e.g., during normal user breathing rates/normal requiredoxygen flow rates). Air from the compressors 301 may enter the oxygenconcentrator 100 through both inlets 109 a and 109 b and may be directedto a canister (e.g., canister 101 a or 101 b) through valves 305 a and305 b (through respective valve seats 105 a, 105 b). At lower userbreathing rates/lower required oxygen flow rates, a subset of thecompressors 301 may be used. For example, only one compressor (301 a or301 b) may be used and the air from the compressor 301 a or 301 b mayenter through inlet 109 a or 109 b. The air may be similarly directedinto a canister 101 a or 101 b through valves 305 a and 305 b (throughrespective valve seats 105 a, 105 b). In some embodiments, when a subsetof the compressors 301 are operating, the subset that is operating mayalternate operating time with the inactive compressors. For example,during single compressor operation, the two compressors 301 mayalternate (e.g., to keep wear evenly distributed between the twocompressors 301). In some embodiments, other numbers of compressors 301may be used. For example, four compressors may be used during normaloperation (e.g., with two compressors placing air into inlet 109 a andtwo compressor placing air into inlet 109 b). With four compressors, asubset of the compressors may include two operating compressors (e.g.,either the two compressors placing air into inlet 109 a or the twocompressors placing air into inlet 109 b or one compressor placing airinto inlet 109 a and one compressor placing air into inlet 109 b). Otherconfigurations are also contemplated. Using a subset of the compressors301 may reduce power consumption during low activity times for the user(e.g., while the user is sitting). The reduced power consumption mayallow for a smaller battery 395 to be used in the oxygen concentrator100.

In some embodiments, a single compressor may be used (e.g., in differentpower modes). For example, during normal operation the compressor may beoperated at full power, while, during lower breathing rates, thecompressor may be operated at a lower power setting. In someembodiments, the compressors in multiple compressor operation may alsobe operated at different power levels (e.g., at lower power settingsduring lower breathing rates).

In some embodiments, if one or more of the compressors fails, the othercompressors may provide at least a subset of the required oxygen to theuser. This may provide oxygen to the user until the user can locateother oxygen arrangements. In some embodiments, one or more of thecompressors may be redundant compressors such that if a compressorfails, the user may still receive the prescribed oxygen rate. In someembodiments, the redundant compressor may be activated when one of theactive compressors fails. In some embodiments, the redundant compressormay have already been active (e.g., additional power may be supplied tothe active compressors when one of the compressors fails).

In some embodiments, the compressors 301 may be controlled through acompressor control system implemented by processor 399 (which mayinclude, for example, one or more field programmable gate arrays(FPGAs), a microcontroller, etc. comprised on circuit board 2607 as seenin FIG. 26) executing programming instructions stored on memory 397. Insome embodiments, the programming instructions may be built intoprocessor 399 such that a memory 397 external to the processor 399 maynot be separately accessed (i.e., the memory 397 may be internal to theprocessor 399). In some embodiments, the processor 399 may be coupled tothe compressors 301. The processor 399 may also be coupled to othercomponents of the oxygen concentrator (e.g., valves 305, oxygen sensor307, demand transducer 331, etc.). In some embodiments, a separateprocessor (and/or memory) may be coupled to the other components of theoxygen concentrator 100. In some embodiments, the demand transducer 331may be a pressure transducer 901 detecting inhalations to detect thebreathing rate (and, for example, the volume). In some embodiments, thedemand transducer 331 may be a separate transducer than the pressuretransducer 901. The information from the demand transducer 331 mayassist the processor 399 in making a determination as to how manycompressors 301 should be operating. For example, if the user has a lowbreathing rate (e.g., less than an average breathing rate), theprocessor 399 may activate only a subset of the compressors 301 (e.g.,one compressor). The user may have a low breathing rate if relativelyinactive (e.g., asleep, sitting, etc.) as determined by comparing thedetected breathing rate to a threshold. In some embodiments, theavailable compressors may be alternately used during low activity cyclesto even out wear over the available compressors (instead ofconcentrating wear on one compressor). If the user has a relatively highbreathing rate (e.g., at or more than an average breathing rate), theprocessor 399 may implement a greater number of compressors (e.g., bothcompressors 301 a-b). The user may have a high breathing rate ifrelatively active (e.g., walking, exercising, etc.). The active/sleepmode may be determined automatically and/or the user may manuallyindicate a respective active or sleep mode (e.g., the user may press abutton 2113 (active)/2115 (sleep) to indicate active or sleep mode(e.g., see FIG. 21 b)). Other numbers of activity settings are alsopossible (e.g., low, moderate, active, and very active). Additionalactivity settings may use different numbers of subsets of compressors301 (or different power levels for the operating compressors).

A user breathing at a rate of 30 breaths per minute (BPM) may consumetwo and one-half times as much oxygen as user who is breathing at 12BPM. As noted above, if the breathing rate of the user is calculated andused to adjust the number of and/or power input to the compressors 301,less power may be used. For example, a user who is more active (e.g.,walking) may consume more oxygen and require more power than the userwho is less active (e.g., sitting or sleeping). In some embodiments, thebreathing rate of the user may thus be detected and the bolus may beadjusted (e.g., by adjusting the power to or the operating number of thecompressors 301) to provide more or less oxygen to allow the oxygenconcentrator 100 to perform more efficiently by meeting the user'schanging oxygen demands without operating at full power continuously.Using less power may reduce power consumption and increase battery lifeand/or decrease battery size requirements.

In some embodiments, if the user's current activity level (e.g., asdetermined using the detected user's breathing rate or some other factorsuch as airflow near the nasal cannula 903) exceeds a threshold (e.g., apredetermined threshold), the processor 399 may implement an alarm(e.g., visual and/or audio) to warn the user that the current breathingrate exceeds a safe operating threshold (and therefore, for example, theuser may not be receiving a prescribed amount of oxygen). For example,the threshold may be set at 20 breaths per minute (other breathingthresholds are also contemplated). In some embodiments, the oxygensensor 307 coupled to the oxygen concentrator 100 may measure an oxygenlevel (e.g., as percent oxygen) in the gas being delivered to the userand an alarm may be activated if the percent oxygen drops below athreshold. In addition, a gas flow meter 1143 may measure a volume ofgas flowing to the user. The volume measurement and percent oxygenmeasurement may provide the volume of oxygen being delivered to the userand an alarm may be activated if the volume drops below a threshold. Insome embodiments, an alarm may be activated if the percent and/or volumeof oxygen exceeds a threshold (e.g., too much oxygen is being deliveredto the user). In some embodiments, the processor 399 may implementseveral levels of alarms (e.g., colored lights to indicate the currentdemand on the oxygen concentrator 100). Alarms may also include auditoryalarms and/or messages provided on LED (Light Emitting Diode) display2105. In some embodiments, if the user's breathing rate exceeds thethreshold and/or one or more compressors is inoperable, the operablecompressors may be driven at a higher power setting (which may be onlytemporarily sustainable over an emergency period). Other compensationtechniques are also contemplated.

In some embodiments, oxygen from the canisters 101 may be stored in anoxygen accumulator 103 in the oxygen concentrator 100 and released tothe user as the user inhales. For example, the oxygen may be provided ina bolus in the first few milliseconds of a user's inhalation. The user'sinhalation may be detected using a demand transducer (e.g., pressuretransducer 901). In some embodiments, the size of the bolus may bereduced if the response time is decreased and, therefore, the oxygenneeded to provide a prescribed flow rate for the user may also bereduced as response time is reduced. Releasing the oxygen to the user asthe user inhales may prevent unnecessary oxygen generation (furtherreducing power requirements) by not releasing oxygen, for example, whenthe user is exhaling. Reducing the amount of oxygen required mayeffectively reduce the amount of air compressing needed for the oxygenconcentrator 100 (and subsequently may reduce the power demand from thecompressors). In some embodiments, the bolus may be 8 cubic centimeters(cc) to provide the equivalent of a prescribed 1 LPM (or 16 ccs for 2LPM or 24 ccs for 3 LPM). Slower responses may require a larger bolus(e.g., 15 or 16 cc for a 1 LPM prescribed rate).

In some embodiments, as seen in FIG. 27, the bolus may include two ormore pulses. For example, with a one liter per minute (LPM) deliveryrate, the bolus may include two pulses: a first pulse 2701 a atapproximately 7 cubic centimeters and a second pulse 2701 b atapproximately 3 cubic centimeters. Other delivery rates, pulse sizes,and number of pulses are also contemplated. For example, at 2 LPMs, thefirst pulse may be approximately 14 cubic centimeters and a second pulsemay be approximately 6 cubic centimeters and at 3 LPMs, the first pulsemay be approximately 21 cubic centimeters and a second pulse may beapproximately 9 cubic centimeters. In some embodiments, the larger pulse2701 a may be delivered when the onset of inhalation is detected (e.g.,detected by demand transducer 331). In some embodiments, the pulses 2701may be delivered when the onset of inhalation is detected and/or may bespread time-wise evenly through the breath. In some embodiments, thepulses 2701 may be stair-stepped through the duration of the breath. Insome embodiments, the pulses 2701 may be distributed in a differentpattern. Additional pulses may also be used (e.g., 3, 4, 5, etc. pulsesper breath). While the first pulse 2701 a is shown to be approximatelytwice the second pulse 2701 b, in some embodiments, the second pulse2701 b may be larger than the first pulse 2701 a. In some embodiments,pulse size and length may be controlled by, for example, valve F 305 gwhich may open and close in a timed sequence to deliver the pulses 2701.A bolus with multiple pulses 2701 may have a smaller impact on a userthan a bolus with a single pulse. The multiple pulses 2701 may alsoresult in less drying of a user's nasal passages and less blood oxygendesaturation. The multiple pulses 2701 may also result in less oxygenwaste.

In some embodiments, silicone rubber tube 197 (FIG. 2 a) may becompliant such that the diameter of the silicone rubber tube 197 mayexpand as the pulses 2701 travel through the silicone rubber tube 197(and then return to a normal diameter between pulses 2701). Theexpansion may smooth out the pulses 2701 such that the pulses 2701 maybe received by the user with a smoother peak. The smoother pulses mayalso be received by the user over a greater time period than the timeperiod for the release of the boluses from valve 305 g.

In various embodiments, the user's inhalation may be detected by usingpressure transducer 901 on nasal cannula 903 detecting a negativepressure generated by venturi action at the start of a user'sinhalation. The pressure transducer 901 may be operable to create asignal when the inhalation is detected to open a supply valve (e.g.,valve 305 g) to release an oxygen bolus from the oxygen accumulator 103.In some embodiments, the pressure transducer 901 may be located at theexit of oxygen concentrator 100 (e.g., see FIG. 9 a) and may detect apressure difference of the air in the tube 907. In some embodiments, thepressure transducer 901 may be located at the end of a tube 907delivering oxygen to the user to detect a pressure difference at theuser's nose. For example, the pressure transducer 901 may use Whetstonebridge microgauges to detect a pressure difference at the exit of theoxygen concentrator 100 or on the nasal cannula 903. Other placements ofthe pressure transducer 901 are also contemplated. Other pressuretransducer types are also contemplated. In some embodiments, a pluralityof pressure transducers may be used. In some embodiments, the pressuretransducer 901 may be disposable.

In some embodiments, pressure transducers 901 may provide a signal thatis proportional to the amount of positive or negative pressure appliedto a sensing surface. The pressure transducers 901 may need to besensitive enough to provide a predictable relationship between theoutput of the pressure transducers 901 and the signal the pressuretransducers 901 deliver. In some embodiments, the processor 399 may useinformation from the pressure transducer 901 to control when the bolusof oxygen should be released. The processor 399 may also control othercomponents based on information from the pressure transducer 901 (e.g.,the sensitivity of the pressure transducer 901, the number of activecompressors 301 and/or the power level of the compressors 301, etc.).

In some embodiments, the sensitivity of the pressure transducer 901 maybe affected by the physical distance of the pressure transducer 901 fromthe user, especially if the pressure transducer 901 is located on theoxygen concentrator 100 and the pressure difference is detected throughthe tubing 907 to the nasal cannula 903. In some embodiments, thepressure transducer sensitivity may not be affected by the length of thetubing 907 because the pressure transducer 901 may be placed in the maskor nasal cannula 903 (e.g., see FIG. 9 b) and a signal from the pressuretransducer 901 may be delivered to a processor 399 in the oxygenconcentrator 100 electronically via wire 905 (which may be co-extrudedwith the tubing 907) or through telemetry such as through Bluetooth™ orother wireless technology (e.g., using a wireless transmitter at thepressure transducer 901 and a wireless receiver at the oxygenconcentrator 100). Placing the pressure transducer 901 on the nasalcannula 903 may allow for a longer delivery tube 907. In someembodiments, the pressure transducer 901 may be placed near a prong onthe nasal cannula used to deliver oxygen into the user's nose.

In some embodiments, a dual lumen tube 909 may be used. One lumen (e.g.,see cross section of lumens 911 a, 911 b, or 911 c) may deliver theoxygen to the user and one lumen 913 (e.g., see cross section of lumens913 a, 913 b, or 913 c) may have a smaller diameter than the first lumen911 and may transfer a pressure difference to the pressure transducer901 mounted in the pressure transducer 901 at the oxygen concentrator100. With a smaller diameter, the second lumen 913 may reduce the volumeof air between the user and the pressure transducer 901 for a givenlength of tubing. As the volume of air is reduced, compliance of apressure spike delivery medium may be reduced and the sensitivity of thepressure transducer 901 may correspondingly be increased. For example,the pressure difference in lumen 913 resulting from a user's inhalationmay be easier to detect at the pressure transducer 901 at the oxygenconcentrator 100 than if the pressure difference were being detectedthrough a lumen with a greater diameter. In some embodiments, thedetectable pressure difference may decrease along the length of thelumen such that at a certain length of lumen, the pressure differencemay not be detectable. Reducing the diameter of the lumen may result inthe pressure difference being easier to detect at farther distances(i.e., because there is less air in the lumen to transmit the pressuredifference and, correspondingly, less transporting air volume to weakenthe pressure difference). The pressure difference may also be detectablemore quickly in a narrow diameter lumen than in a lumen with a greaterdiameter. In some embodiments, the dual lumen 909 may take on theconfiguration shown in FIG. 9 d or 9 e. Other configurations are alsocontemplated. In some embodiments, the dual lumens 909 may beco-extruded plastic. Other manufacturing techniques and materials arealso contemplated.

Pressure transducer 901 may detect a pressure difference and/or aquantitative measurement of the inhalation pressure drop. Detecting theuser's inhalation may not require a quantitative measurement of theinhalation pressure difference, but may rely on a temporal indicator tosense the inhalation. In some embodiments, devices other than or inaddition to pressure transducers 901 may be used to detect a user'sinhalation. For example, in some embodiments, a Hall-effect sensor 1001(see FIG. 10) may be used to detect a user's inhalation. The Hall-effectsensor 1001 may include a vane 1003 with a magnet 1007 on the vane 1003.The vane 1003 may be positioned in the nasal cannula 903 and a secondmagnet 1005 (e.g., a rare earth magnet) may be arranged to assist indetection of movement of the magnet 1007 on the vane 1003 (using theHall-effect) relative to the Hall-effect sensor 1001. For example, whenthe vane 1003 is detected moving toward the second magnet 1005 (e.g.,through the effect on a current in wire 1009 to the changing magneticfield), the sensor 1001 may indicate a negative pressure (which maycorrespond to the beginning of a user inhalation). For example, airmovement toward the user's nose as the user begins taking a breath maymove the vane 1003 toward the second magnet 1005. The Hall-effect sensor1001 may provide a more sensitive detector of the time the inhalationbegins in the users breathing cycle. In some embodiments, the signalfrom the Hall-Effect sensor 1001 may be sent down wire 905 (orwirelessly transmitted). Other magnet-based sensors may also be used(e.g., a small magnet moved by the user's inhalation that acts to closea circuit). Other Boolean type sensors may be used.

In some embodiments, the sensitivity of the oxygen concentrator 100 maybe selectively attenuated to reduce false inhalation detections due tomovement of air from a different source (e.g., movement of ambient air).For example, the oxygen concentrator 100 may have two selectablemodes—an active mode and an inactive mode. In some embodiments, the usermay manually select a mode (e.g., through a switch or user interface).In some embodiments, the mode may be automatically selected by theoxygen concentrator 100 based on a detected breathing rate. For example,the oxygen concentrator 100 may use the pressure transducer 901 todetect a breathing rate of the user. If the breathing rate is above athreshold, the oxygen concentrator 100 may operate in an active mode(otherwise, the oxygen concentrator may operate in an inactive mode).Other modes and thresholds are also contemplated.

In some embodiments, in active mode, the sensitivity of the pressuretransducer 901 may be mechanically, electronically, or programmaticallyattenuated. For example, during active mode, the processor 399 may lookfor a greater pressure difference to indicate the start of a user breath(e.g., an elevated threshold may be compared to the detected pressuredifference to determine if the bolus of oxygen should be released). Insome embodiments, the pressure transducer 901 may be mechanicallyaltered to be less sensitive to pressure differences. In someembodiments, an electronic signal from the pressure transducer 901 maybe electronically attenuated to indicate a smaller pressure differencethan detected at the pressure transducer 901 (e.g., using a transistor).In some embodiments, during the inactive mode the sensitivity of thepressure transducer 901 may not be attenuated (e.g., the sensitivity ofthe pressure transducer 901 may be increased during sleep periods). Forexample, the processor 399 may look for a smaller pressure difference toindicate the start of a user breath (e.g., a smaller threshold may becompared to the detected pressure difference to determine if the bolusof oxygen should be released). In some embodiments, with increasedsensitivity, the response time for delivery of the bolus of oxygenduring the user's inhalation may be reduced. The increased sensitivityand smaller response time may reduce the size of the bolus necessary fora given flow rate equivalence. The reduced bolus size may also reducethe size and power consumption of the oxygen concentrator 100 that mayreduce the size of a battery 395 needed to operate the oxygenconcentrator (which may make the oxygen concentrator smaller and moreportable).

FIG. 11 illustrates a circuit diagram of an ultrasonic sensor assembly,according to an embodiment. In some embodiments, the oxygen sensor 307may be an ultrasonic sensor that may be used to measure an oxygen levelor the percent oxygen in the gas being delivered to the user. Other usesof the ultrasonic sensor assembly are also contemplated (e.g., todetect/measure the presence of other gases for other devices). Anultrasonic sound wave (from emitter 201) may be directed through achamber 1101 containing a sample of the gas mixture (e.g., from thesupply line providing oxygen to the user) to receiver 203. The sensor307 may be based on detecting the speed of sound through the gas mixtureto determine the composition of the gas mixture (e.g., the speed ofsound is different in nitrogen and oxygen). In a mixture of the twogases, the speed of sound through the mixture may be an intermediatevalue proportional to the relative amounts of each in the mixture. Insome embodiments, the concentration of oxygen may be determined bymeasuring the transit time between an emitter 201 and the receiver 203.In some embodiments, multiple emitters 201 and receivers 203 may beused. Emitters 201 may be axially aligned with respective receivers 203.Other configurations are also contemplated. The readings from theemitters 201 and receivers 203 may be averaged to cancel errors that maybe inherent in turbulent flow systems. In some embodiments, the presenceof other gases may also be detected by measuring the transit time andcomparing the measured transit time to predetermined transit times forother gases and/or mixtures of gases.

In some embodiments, a zero-crossing point of the sound wave 1205 may beused as a reference point for these measurements (other points may alsobe used). The sensitivity of the sensor 307 may be increased byincreasing the distance between the emitter 201 and receiver 203 (e.g.,to allow several sound wave cycles to occur between the emitter 201 andthe receiver 203). In some embodiments, if at least two sound cycles arepresent, the influence of structural changes of the transducer may bereduced by measuring the phase shift relative to a fixed reference attwo points in time. If the earlier phase shift is subtracted from thelater phase shift, the shift caused by thermal expansion of thetransducer housing may be reduced or cancelled. The shift caused by achange of the distance between the emitter 201 and receiver 203 may bethe approximately the same at the measuring intervals, whereas a changeowing to a change in oxygen concentration may be cumulative. In someembodiments, the shift measured at a later time may be multiplied by thenumber of intervening cycles and compared to the shift between twoadjacent cycles.

In some embodiments, a pulse generator 1103 may send an enable pulse1105 to a NAND gate U2 1107, which may channel a 40 kHz excitationsignal to the emitter 201, via amplifier U1 1109. Other excitationssignals are also contemplated. After traversing the gaseous mixture inthe chamber 1101, the ultrasonic sound wave may impinge on the receiver203, and in the process, may undergo a phase shift, relative to theexcitation signal. The gas may be introduced (prior to or during thesound wave transmission) into the chamber 1101 via ports 1131 a,b thatare perpendicular to the direction of the sound wave. Thevelocity-induced components of the phase shift may be reduced orcancelled. Turbulence may create a uniform gaseous mixture in thechamber 1101. A change in the composition of the gas may affect thesound velocity of the sound wave traveling between the emitter 201 andthe receiver 203. A higher concentration of oxygen may correspond to alower sound velocity (and, correspondingly, more phase shift). The soundwave captured by the receiver 203 may be amplified by U3 1111 and putinto a zero-crossing detector U4 1113 (which may provide zero crossingpulse 1207 to flip-flop U5 1117). The pulse generator 1103 may providereference pulse 1 1115 to flip-flop U5 1117, clear the flip-flop U5 1117and the output 1207 of the zero-crossing detector 1113, and create anegative-going pulse to gate pulse 1 1201, as shown in FIG. 12. Thelength of this pulse may correspond to the phase shift occurring in theinterval T2-T1. In an analogous fashion, gating pulse 2 1203 may bederived in the interval T4-T3 (e.g., with reference pulse 2 1209 andzero crossing pulse 2 1211 provided to flip-flop U6 1135). Phase shiftscaused by structural changes in the transducer housing may be reduced orcancelled by subtracting interval T2-T1 from interval T4-T3. Anembodiment of the process is illustrated in FIG. 14. The integrator 1133may be zeroed to reduce or eliminate drift that may have accrued sincethe last operation. Then, the subtraction gate 1407 may be opened bygating pulse 1 1201. After the gate has closed, the voltage at theintegrator output may be V1 (see 1401 in FIG. 14):V1=K1×(St+Sc)(where St is the phase shift caused by temperature 1301, Sc is the phaseshift caused by changes in oxygen concentration 1303, andK1=t/RC×(−Vref), where RC is a reflection coefficient and Vref is thereference voltage). After the gate has closed, the integrator output1407 may remain stable until the addition gate 1409 opens. (The flatsections in the figure have been omitted for clarity.) After thetermination of the addition gating pulse, the output voltage may be V2(see 1403 in FIG. 14):V2=K1×[(St+Sc)−(St+2×Sc)]=K1×ScTermination of the addition gate may clear flip-flop U7 1119, which mayoutput a gating pulse that opens the calibrating gate, U8C 1121. U7 1119may be set by U4 1113, when V3=0 (see 1403):V3=V2−K2×t=0; K1×Sc=K2×t; t=K1/K2×Sc(where K2=t/RC×(+Vref)). The length of the negative-going pulse from U71119 may be proportional to the phase shift Sc. An embodiment of therelationship between St and Sc is shown in FIG. 13. The pulse generatorshown in FIG. 11 may issue a concentration reference pulse 1413 whoselength is set to correspond to, for example, the minimum acceptableoxygen concentration (e.g., as defined by the user's prescription orother source). As shown in FIG. 14, low oxygen concentration may causethe zero crossing to occur earlier and make both inputs of U11 1123 highat the same time. The resulting pulse may be used to activate an audiblealarm 1139 (through amplifier U12 1141) to alert the user that theoxygen concentration may be too low. The point at which the alarm istriggered may be set by adjusting P2 1125, (e.g., see FIG. 11). Thevelocity of sound may increase with temperature (which may incorrectlyindicate a decrease in oxygen concentration). This effect may be reducedor cancelled by using a thermistor 1127 whose resistance increases withtemperature to restore the duration of the concentration pulse to acorrected value. The amount of correction introduced may be varied byadjusting P1 1129. FIG. 6 a-h shows the sensor constructed with discretecomponents. In some embodiments, the processing may be performed by aprocessor 399 (e.g., a field programmable gate array (FPGA)).

In some embodiments, the oxygen sensor 307 may include a gas flow meter1143 that uses the Doppler effect to measure the volume of gas flow pastthe sensor. With the volume measurement from the gas flow meter 1143 andthe percent oxygen reading from the ultrasonic sensor, the amount ofoxygen delivered to the user may be measured and controlled. Forexample, if the concentration of oxygen is greater than a desiredpercentage, (e.g., as indicted by the length of the concentrationreference pulse 1413), then the user is receiving at least a volume ofoxygen equal to the volume of gas flow*the desired percentage of oxygen.In some embodiments, one or more signals from the ultrasonic sensor maybe relayed to the processor 399 for a determination of an actualpercentage of oxygen in the sample. For example, the processor 399 mayreceive an indication of gating pulse 1201, gating pulse 1203, and/orconcentration reference pulse 1413 to determine an approximatepercentage of oxygen in the gas sample. Other signals may also be used.Using a gas flow meter 1143 that uses the Doppler effect to measure thevolume of gas flow may be more accurate than simply using time, pressureand orifice size to determine delivered volume.

In some embodiments, the battery 395 may be a rechargeable lithiumbattery. Other battery types are also contemplated. Larger batteries maybe used for longer battery life. Smaller batteries may have a shorterbattery life, but may be lighter. In some embodiments, a battery largeenough to provide a battery life of 2 hours (using the various powersaving mechanisms discussed herein) may be used. Other batterylifetimes/sizes are also contemplated. As seen in FIG. 15, in someembodiments, additional power may be provided to the oxygen concentrator100 through a solar powered recharging circuit including solar panel1501 so that the battery 395 may be supplemented to increase batterylife or reduce battery size (e.g., especially while the user may beconsuming more oxygen (and thus more power) outdoors). In someembodiments, an alternating current power adapter may be provided tocharge the battery and/or provide power to the oxygen concentrator.Other power sources are also contemplated (e.g., an adapter to allow theoxygen concentrator to be plugged into a power outlet in an automobile).

FIG. 16 illustrates a flowchart of an embodiment for oxygen concentratoroperation, according to an embodiment. It should be noted that invarious embodiments of the methods described below, one or more of theelements described may be performed concurrently, in a different orderthan shown, or may be omitted entirely. Other additional elements mayalso be performed as desired.

At 1601, air may be pulled into the compressor 301. The compressor mayinclude, for example, dual-pump diaphragm compressors 301 a-b. The airmay pass through a moisture and sound absorbing muffler 393 prior toentering the compressor 301. For example, a water absorbent (such as apolymer water absorbent) may be used. Other absorbents may also be used.

At 1603, air from the compressor 301 may be delivered to a firstcanister 101 a comprising zeolite 391. The air from the compressor 301may be directed through one or more valves 305 on the path to the firstcanister 101 a. The valves 305 may be coupled to and controlled by amicroprocessor (e.g., processor 399).

At 1605, a gas mixture (which may be comprised of mainly oxygen) may bedelivered out of the first canister 101 a and into an oxygen accumulator103. In some embodiments, the gas mixture may pass through a check valve123 a (e.g., a butterfly check valve) between the first canister 101 aand the oxygen accumulator 103. In some embodiments, a pressuretransducer 389 may detect a pressure of the oxygen accumulator 103. Thepressure of the oxygen accumulator may be used, for example, by theprocessor to determine if one or more of the canisters has a leak, etc.Other uses for the pressure are also contemplated.

At 1607, an inhalation may be detected by the user through a demandtransducer 331 (e.g., pressure transducer 901).

At 1609, the gas mixture from the oxygen accumulator 103 may be passedthrough an oxygen sensor 307 (e.g., an ultrasonic sensor) to detect aconcentration of oxygen in the gas mixture. The sensor may also includeor be coupled to a gas flow meter 1143 to detect a volume of the gaspassing the gas flow meter 1143.

At 1611, the gas mixture may pass through a tube (e.g., tube 907 or tube909) to be delivered to the user through a nasal cannula 903. In someembodiments, the gas mixture may be delivered to the user in a singlepulse or in two or more pulses (e.g., see FIG. 27).

At 1613, air from the compressor 301 may be delivered into the secondcanister 101 b comprising zeolite 391.

At 1615, a gas mixture (which may be comprised of mainly oxygen) may bedelivered out of the second canister 101 b and into the oxygenaccumulator 103.

At 1617, nitrogen from the first canister 101 a may be purged from thefirst canister 101 a by releasing a pressure (e.g., by opening valve 305c or 305 d (and closing valves 305 a and 305 b) to open up an airpathway between the first canister 101 a and the output vent 327) fromthe first canister 101 a.

At 1619, oxygen from the oxygen accumulator 103 may be passed through anopposite end of the first canister 101 a to further purge the nitrogenfrom the first canister 101 a.

At 1621, nitrogen from the first canister 101 a may pass through amuffled output vent 327 and out of the oxygen concentrator 100.

At 1623, air from the compressor 301 may be delivered into the firstcanister 101 a comprising zeolite 391.

At 1625, a gas mixture (which may be comprised of mainly oxygen) may bedelivered out of the first canister 101 a and into an oxygen accumulator103.

At 1627, nitrogen from the second canister 101 b may be purged from thesecond canister 101 b by releasing a pressure from the second canister101 b.

At 1629, oxygen from the oxygen accumulator 103 may be passed through anopposite end of the second canister 101 b to further purge the nitrogenfrom the second canister 101 b.

FIG. 17 illustrates a flowchart of an embodiment for oxygen concentratorassembly, according to an embodiment. It should be noted that in variousembodiments of the methods described below, one or more of the elementsdescribed may be performed concurrently, in a different order thanshown, or may be omitted entirely. Other additional elements may also beperformed as desired.

At 1701, a first housing component 111 a of the oxygen concentrator 100may be injection molded. The first housing component 111 a may includeinternal air pathways and zeolite canisters 101. In some embodiments, aninverted mold may be formed (with solid portions corresponding to theair pathways/inner canisters of the first housing component 111 a) andplaced inside a container with an inner shape with dimensions similar tothe outer dimensions of the first housing component 111 a. Spacers maybe added between the solid portions and the container to hold the solidportions relative to the container. A plastic (e.g., a liquidthermoplastic) may be injected into the spaces between the outercontainer and the solid portions to form the injection molded firsthousing component 111 a. The mold (comprising the container and solidportions) may then be removed and/or broken away. In some embodiments,the mold may be melted away from the injection molded first housingcomponent 111 a after the injection molded first housing component 111 ahas cooled. Other methods of injection molding are also contemplated.Other molding techniques are also contemplated.

At 1703, a second housing component 111 b of the oxygen concentrator 100may be injection molded. The second housing component 111 b may includeinternal air pathways and endcaps for the zeolite canisters 101.

At 1705, spring baffles 129 may be placed into the endcaps for thezeolite canisters on the second housing component 111 b. In someembodiments, the spider legs 701 of the spring baffle 129 may engage theridges 133 on the back of the canisters 101 a,b.

At 1707, filters (e.g., filters 207) may be fastened to the inner end ofthe zeolite canisters on the first housing component 111 a and the innerend (end without the spider legs) of spring baffles 129 in the secondhousing component 111 b.

At 1709, O-rings 135 may be added between air pathways 121 between thefirst housing component 111 a and the second housing component 111 b.For example, O-rings 135 may be placed between the endcaps for thezeolite canisters 101 on the second housing component 111 b and thezeolite canisters 101 on the first housing component 111 a. OtherO-rings may also be used.

At 1711, zeolite 391 may be added to the zeolite canisters 101 and thefirst housing component 111 a and the second housing component 111 b maybe fastened together (e.g., through an adhesive, solvent weld, etc.).

At 1713, press fit flow restrictors (e.g., press fit flow restrictors311, 321, 323, and 325) may be inserted into apertures (e.g., formedduring the injection molding process) of the first housing component 111a and/or the second housing component 111 b.

At 1715, plugs (e.g., plugs 127) may be inserted and fastened into theapertures to seal the apertures. For example, the plugs may be fastenedthrough the use of an adhesive or solvent weld. Other fasteningtechniques are also contemplated.

At 1717, check valves 123 may be inserted into and fastened (e.g.,through an adhesive) to the first housing component 111 a and/or secondhousing component 111 b.

At 1719, an ultrasonic sensor emitter 201 and receiver 203 may beinserted into and fastened to the second housing component. For example,the ultrasonic sensor emitter 201 and receiver 203 may be coupled to thesecond housing component through an adhesive or friction fit. In someembodiments, multiple ultrasonic sensor emitters 201 and ultrasonicreceivers 203 may be used. Emitters 201 may be axially aligned withrespective receivers 203 such that the gas flows perpendicular to theaxis of alignment. Other configurations are also contemplated.

At 1721, valves (e.g., valves 305) may be fastened to the first housingcomponent 111 a and/or the second housing component 111 b (e.g., screwedonto the exterior). Other fastening techniques for the valves are alsocontemplated (e.g., adhesive).

At 1723, one or more compressors 301 may be coupled to the canisters 101of the first housing component (e.g., through one or more tubes 199coupled to valves 305 coupled to the first housing component).

At 1725, the ultrasonic emitter 201 and receiver 203, valves, and one ormore compressors may be wired to one or more microcontrollers (e.g.,processor 399). Other electronic components may also be coupled to themicrocontrollers. For example, an on/off button 2103 a,b and an LEDdisplay 2105 a,b (see FIGS. 21 a,b) to convey information such as lowoxygen or low power warnings to the user.

At 1727, a battery 395 may be electrically coupled to the ultrasonicemitter 201 and receiver 203, valves, one or more compressors 301, andone or more microcontrollers. The battery 395 may also be electricallycoupled to other components of the oxygen concentrator 100. In someembodiments, the battery 395 may be electrically coupled to componentsof the oxygen concentrator 100 through other components (e.g., thebattery 395 may be coupled to the valves 305 through the processor 395).

At 1729, open cell foam and the vent 401 may be coupled to the firsthousing component 111 a (e.g., the foam may be inserted into the ventout 137 and vent 401 may be fastened over the vent out 137 through, forexample, an adhesive).

At 1731, the oxygen concentrator components (e.g., first housingcomponent 111 a, second housing component 111 b, battery 395,compressors 301, etc.) may be packaged together into an outer housing2101 a,b (e.g., see FIGS. 21 a,b). In some embodiments, the outerhousing 2101 may be a durable, light-weight plastic. Other materials arealso contemplated. Other outer housing configurations are alsocontemplated. In some embodiments, the components may be placed in anfoam housings 2401 (see FIGS. 24-25) and the foam housings 2401 may beplaced inside an enclosure housing 2201 before being placed inside outerhousing 2101.

At 1733, a tube (e.g., tube 907 or 909) with a nasal cannula 903 may becoupled to the oxygen outlet 107. If a dual lumen is used, lumen 913 maybe coupled to a pressure transducer 901 coupled to the oxygenconcentrator 100.

FIG. 18 illustrates a flowchart of an embodiment for compressor control,according to an embodiment. It should be noted that in variousembodiments of the methods described below, one or more of the elementsdescribed may be performed concurrently, in a different order thanshown, or may be omitted entirely. Other additional elements may also beperformed as desired.

At 1801, a breathing rate of the user may be detected (e.g., bydetermining how may inhalations pressure sensor 901 detects per minute).

At 1803, a determination may be made as to whether the breathing rate isbelow a first threshold. The first threshold may be, for example, 15breaths per minute (other thresholds are also contemplated). In someembodiments, the threshold may be predetermined and/or may be variable(e.g., adjusted according to an external temperature detected by atemperature sensor coupled to the oxygen concentrator 100). In someembodiments, the threshold may be set by the user (or, for example, by adoctor's prescription).

At 1805, if the breathing rate is below a first threshold, a subset ofthe compressors may be used (e.g., one of two compressors may be used).Using a subset of compressors may lower power requirements and conservethe battery. In some embodiments, the user may manually place the oxygenconcentrator 100 into a lower power mode that uses a subset of thecompressors 301.

At 1807, if the breathing rate is above the first threshold, a greaternumber than the subset of compressors may be used (e.g., two of twocompressors may be used). In some embodiments, if one or more of theavailable compressors malfunctions, all of the available compressors maybe used (regardless of detected breathing rate) until the compressor canbe repaired. In some embodiments, fewer than all of the availablecompressors may be used if another compressor malfunctions.

FIG. 19 illustrates a flowchart of an embodiment for ultrasonic sensoroperation, according to an embodiment. It should be noted that invarious embodiments of the methods described below, one or more of theelements described may be performed concurrently, in a different orderthan shown, or may be omitted entirely. Other additional elements mayalso be performed as desired.

At 1901, an ultrasonic sound wave may be produced by the ultrasonicemitter 201.

At 1903, the ultrasonic sound wave may pass through a sample of gasmixture (e.g., which may be comprised of mostly oxygen) in a chamberbetween the emitter 201 and receiver 203.

At 1905, the ultrasonic sound wave may be received by the ultrasonicreceiver 203.

At 1907, the transit time for the sound wave may be determined.

At 1909, the transit time for the sound wave through the gas mixture maybe compared to predetermined transit times for other gases to determinean approximate concentration of the gas constituents of the mixture. Insome embodiments, a phase shift due to structural changes in the housingmay be accounted for in the comparison.

FIG. 20 illustrates an embodiment of a headset/microphone boom 2003. Insome embodiments, a device 387 (e.g., an MP3 player, mobile phone, etc.)may be integrated into the oxygen concentrator 100 (e.g., integratedinto the outer housing 2101). The microphone 2005 and headphones 2007may be coupled to the device through a wire 2001 (e.g., which may becoextruded with the tube 909, coupled to wire 905, or wire 2001 and wire905 may be one wire). The oxygen concentrator may have an audiooutput/input jack 2109 (other locations of the audio/input jack 2109 arealso contemplated). In some embodiments, the headset 2003 may bewireless (e.g., may use Bluetooth™). In some embodiments, the microphone2005 may be coupled to the nasal cannula 903 and the headphones 2007 maybe coupled to wire 905. Other configurations are also contemplated. Forexample, the oxygen from the oxygen concentrator may be directed at theuser's nose and/or mouth from a tube coupled to microphone 2005 (insteadof or in addition to a nasal cannula). The microphone 2005 may beembedded in the tube directing the oxygen toward the user's nose and/ormouth (and, correspondingly, may be near the user's mouth). Theheadset/microphone boom 2003 may also be used with the oxygenconcentrator 100 for hands-free cellular phone use. Other uses are alsocontemplated.

FIGS. 21 a-c illustrate two embodiments of an outer housing 2101 a,b. Insome embodiments, the outer housing 2101 a,b may be comprised of alight-weight plastic. Other materials are also contemplated. Other outerhousing configurations are also contemplated. In some embodiments, outerhousing 2101 b may include buttons to activate active mode 2113, sleepmode 2115, dosage buttons (e.g., 1 LPM button 2117 a, 2 LPM button 2117b, and 3 LPM button 2117 c), and a battery check button 2119 (which mayresult in a relative battery power remaining LED being illuminated inLED panel 2105 b). In some embodiments, one or more of the buttons mayhave a respective LED that may illuminate when the respective button ispressed (and may power off when the respective button is pressed again).Other buttons and indicators are also contemplated. In some embodiments,outer housing 2101 b may include inlet air slot 2121 for receivingexternal air. Vent 2123 may be used to vent air (e.g., nitrogen) fromthe oxygen concentrator. In some embodiments, a vent 2123 may also be onthe opposing side of the outer housing 2101 b. Plug receptacle 2125 mayplug into an external power adapter or battery pack (e.g., receiveconnector 2823 as seen in FIG. 28 c). Other power sources are alsocontemplated. In some embodiments, the solar panel 1501 may be coupledto an outside of the outer housing 2101 a,b. In some embodiments, thesolar panel 1501 may be coupled to an exterior of a backpack thatreceives the oxygen concentrator.

FIG. 22 illustrates an embodiment of an enclosure housing 2201. FIG. 23illustrates an embodiment of two half sections 2201 a,b of the enclosurehousing 2201. In some embodiments, a section of foam 2203 may beincluded between the enclosure housing 2201 and the outer housing 2101.For example, the foam may be approximately ¼ inch thick. Otherthicknesses are also contemplated. The foam may reduce vibrationtransferred to the outer housing 2101 and/or user. The reduction invibration may reduce noise (e.g., reduce noise by 1 decibel) from theoxygen concentrator while operating. Other sound reduction levels arealso contemplated. In some embodiments, the foam may substantiallysurround the enclosure housing 2201. In some embodiments, the componentsof the oxygen concentrator 100 may be placed inside of foam housings(e.g., FIG. 24 illustrates an embodiment of a first foam housing 2401 aand FIG. 25 illustrates an embodiment of a complimentary second foamhousing 2401 b) and the foam housings 2401 may be placed inside theenclosure housing half sections 2201 a,b. The enclosure housing halfsections 2201 a,b may be coupled together (e.g., through an adhesive,solvent weld, rivets, etc.) to form enclosure housing 2201. Theenclosure housing 2201 may be made of a light-weight plastic. Othermaterials are also contemplated. The enclosure housing 2201 may then beplaced in the outer housing 2101. The foam housings 2401 may becomprised of open cell foam or closed cell foam (which may reduce moreinternal sound). Other materials for the foam housings 2401 are alsocontemplated. In some embodiments, the foam housings 2401 a,b may beseparately coupled together (e.g., sealed together through an adhesiveor solvent weld). In some embodiments, the oxygen concentratorcomponents may not be rigidly mounted to the enclosure housing 2201, butmay be held by the foam (which may also protect the components, forexample, from outer forces on the oxygen concentrator). The placement ofthe oxygen concentrator components in the foam may be aligned forefficiency to reduce the size and weight of the oxygen concentrator.

FIG. 26 illustrates a side and front profile of a component arrangementin the foam housings 2401, according to an embodiment. The foam housings2401 may be configured to conform to the oxygen concentrator components(e.g., compressors 301 a,b, housing components 111 a,b, batteries 395a,b, fans 2601 a,b, etc.). For example, the foam housings 2401 may beconfigured with pockets to receive the oxygen concentrator components.The foam housings 2401 may also incorporate airflow passages 2603 a-d(e.g., cutouts in the foam). Air may be pulled into (e.g., through vent2203) and/or moved around in the foam housings 2401 through fans 2601a,b. In some embodiments, vent 2203 may comprise a sonic baffle with afelt air filter. Other air filters are also contemplated. Air enteringthe vent 2203 may be filtered by the felt prior to entering thecompressors 301. Air may move through air pathways/channels in the foam.The channeled foam may reduce/baffle the sound of the air movement. Insome embodiments, the expansion and contraction of the sound (e.g., asthe sound/air passes through vent 2203) may reduce the sound. The fans2601 may be, for example, 12 volt, 1-inch square fans. Other types,numbers, and placements of fans may also be used. Warm air and/ornitrogen may exit the enclosure housing 2201 through vent 2205, 2605 andthrough outer housing 2101 through a corresponding vent (e.g., vent2107).

In some embodiments, two compressors 301 a,b may be used (e.g., twodual-pump diaphragm compressors). In some embodiments, the twocompressors 301 a,b may be 12 volt compressors. In some embodiments,each compressor may be attached to a fan 2601 (e.g., compressor 301 amay be electrically coupled to fan 2601 a and compressor 301 b may beelectrically coupled to fan 2601 b). In some embodiments, increasing ordecreasing power to a compressor (e.g., compressor 301 a) may result ina corresponding increase or decrease in power to the compressor'scorresponding fan (e.g., fan 2601 a). This may further conserve power bydecreasing power to a fan when the fan's corresponding compressor isoperating under decreased power (and vice-versa). Other compressor/fanarrangements are also contemplated.

In some embodiments, the airflow passages 2603 a-d may be used to forentering cooling air, exiting warm air, nitrogen, etc. In someembodiments, the foam housings 2401 may dampen sound and insulate heatfrom the oxygen concentrator components (e.g., to prevent hot spots onthe outer casings from the oxygen concentrator components). Otherconfigurations of the foam housings 2401 are also contemplated. Forexample, foam may be applied around the oxygen concentrator componentsand allowed to set. In some embodiments, materials other then foam maybe used.

In some embodiments, passages in the foam housings 2401 may be used forelectrical connections. For example, passage 2403 may be used forconnections (e.g., wires) from the batteries 395 to various componentsof the oxygen concentrator (e.g., compressors 301, circuit board 2607,etc.). Passages 2405 and 2407 may also be used for electricalconnections. Passages may also be provided for air tubes. For example,passages 2501 a and 2501 b may be provided for air tubes between thecompressors 301 and the housing component 111 a. In some embodiments,the oxygen may exit through a tube through passage 2407 and through exitport or exit nozzle 2111 a,b in the outer casing (other exit locationsare also contemplated).

FIGS. 28 a-d illustrate an attachable external battery pack 2807 for theoxygen concentrator, according to an embodiment. In some embodiments, anouter covering 2801 on the oxygen concentrator may include variousfasteners for coupling the oxygen concentrator to external battery pack2807. For example, Velcro™ receiving portions 2811 a,b may receiveVelcro™ tabs 2805 a,b, respectively. For example, Velcro™ receivingportions 2811 a,b may include Velcro™ loops and tabs 2805 a,b mayinclude Velcro™ hooks. Other configurations are also contemplated. Insome embodiments, straps 2803 a,b may loop through receiving rings 2813a,b, respectively. The straps 2803 a,b may be pulled through theirrespective rings 2813 a,b, and then the strap may be folded over (withthe fold aligned with the rings 2813 a,b). Straps 2803 a,b may also haveVelcro™ portions. For example, Velcro™ portions 2831 a,b (e.g., hookportions) may engage respective Velcro™ portions 2829 a,b (e.g., loopportions) when the straps 2803 a,b are folded over (after passagethrough their respective hooks 2813 a,b). Other Velcro™ placements arealso contemplated (e.g., between a top of external battery pack 2807 andthe bottom of cover 2801). Other fastener types are also contemplated(e.g., adhesive, tape, buckles, etc). In some embodiments, the covering2801 may include one or more mesh vents (e.g., vents 2819 a,b, and 2815a,b). Covering 2801 may also include belt loops 2821 a,b to receive auser belt (e.g., to hold the oxygen concentrator on a user's waist).Rings 2817 a,b may be used to attach a shoulder strap to carry theoxygen concentrator over a user's shoulder (e.g., a strap withrespective Velcro™ portions may be inserted through each ring and theVelcro™ portions folded over on each other). In some embodiments, theexternal battery pack 2807 may include a connector 2823 to plug into areceiving connector (e.g., plug receptacle 2125 in FIG. 21 c) on theoxygen concentrator to deliver power from the batteries in the externalbattery pack 2807. The external battery pack 2807 may include, forexample, 16 cells to deliver direct current (other battery types andcell numbers are also contemplated). The battery pack 2807 may alsoinclude a battery power indicator 2809. For example, a series of lightemitting diodes (LEDs) 2827 may light up to indicate an amount ofbattery power remaining (e.g., 0%, 25%, 50%, 75%, 100%, etc). Otherindicators are also contemplated. In some embodiments, the externalbattery pack 2807 may include feet 2825 a,b. In some embodiments, thecovering 2801 may be made of canvas, nylon, plastic, etc. Othermaterials for the covering are also contemplated. In some embodiments,rings 2813 a,b and 2817 a,b may be made of stainless steel, plastic,etc. Rings 2813 a,b and 2817 a,b may be fastened to the covering 2801through adhesive, through sewed-on patches (e.g., which overlap aportion of the respective ring), etc. Feet 2825 a,b may be made ofrubber (other materials for the feet 2825 a,b are also contemplated).

Embodiments of a subset or all (and portions or all) of the above may beimplemented by program instructions stored in a memory medium (e.g.,memory 397) or carrier medium and executed by a processor (e.g.,processor 399). A memory medium may include any of various types ofmemory devices or storage devices. The term “memory medium” is intendedto include an installation medium, e.g., a Compact Disc Read Only Memory(CD-ROM), floppy disks, or tape device; a computer system memory orrandom access memory such as Dynamic Random Access Memory (DRAM), DoubleData Rate Random Access Memory (DDR RAM), Static Random Access Memory(SRAM), Extended Data Out Random Access Memory (EDO RAM), Rambus RandomAccess Memory (RAM), etc.; or a non-volatile memory such as a magneticmedia, e.g., a hard drive, or optical storage. The memory medium maycomprise other types of memory as well, or combinations thereof. Inaddition, the memory medium may be located in a first computer in whichthe programs are executed, or may be located in a second differentcomputer that connects to the first computer over a network, such as theInternet. In the latter instance, the second computer may provideprogram instructions to the first computer for execution. The term“memory medium” may include two or more memory mediums that may residein different locations, e.g., in different computers that are connectedover a network.

In some embodiments, a computer system at a respective participantlocation may include a memory medium(s) on which one or more computerprograms or software components according to one embodiment of thepresent invention may be stored. For example, the memory medium maystore one or more programs that are executable to perform the methodsdescribed herein. The memory medium may also store operating systemsoftware, as well as other software for operation of the computersystem.

Further modifications and alternative embodiments of various aspects ofthe invention may be apparent to those skilled in the art in view ofthis description. Accordingly, this description is to be construed asillustrative only and is for the purpose of teaching those skilled inthe art the general manner of carrying out the invention. It is to beunderstood that the forms of the invention shown and described hereinare to be taken as embodiments. Elements and materials may besubstituted for those illustrated and described herein, parts andprocesses may be reversed, and certain features of the invention may beutilized independently, all as would be apparent to one skilled in theart after having the benefit of this description of the invention.Changes may be made in the elements described herein without departingfrom the spirit and scope of the invention as described in the followingclaims.

We claim:
 1. A method of providing oxygen enriched gas to a user of an oxygen concentrator, the oxygen concentrator comprising: at least a first canister and a second canister; separation material disposed in at least the first canister and the second canister, wherein the separation material separates at least some nitrogen from air in the canister to produce oxygen enriched gas; a compression system coupled to at least one canister, wherein the compression system compresses air during operation; a first conduit connecting an outlet of the first canister to an outlet of the second canister, the first conduit comprising a first valve; and a second conduit connecting the outlet of the first canister to the outlet of the second canister, the second conduit comprising a second valve; the method comprising: operating the compression system to compress air; passing the compressed air into one or more of the canisters, wherein oxygen is at least partially separated from air in one or more of the canisters to produce oxygen enriched gas; directing the oxygen enriched gas to the user; venting nitrogen gas from the second canister; diverting at least a portion of oxygen enriched gas produced in the first canister through the first conduit directly into the second canister and diverting at least a portion of oxygen enriched gas produced in the first canister through the second conduit directly into the second canister during the venting of the second canister; venting nitrogen gas from the first canister; and diverting at least a portion of oxygen enriched gas produced in the second canister through the first conduit directly into the first canister and diverting at least a portion of oxygen enriched gas produced in the second canister through the second conduit directly into the first canister during the venting of the first canister.
 2. The method of claim 1, wherein the first conduit and the second conduit are integrated into a molded housing.
 3. The method of claim 1, wherein the oxygen concentrator further comprises an accumulation chamber coupled to one or more of the canisters, wherein the method further comprises directing the oxygen enriched gas produced in one or more of the canisters into the accumulation chamber.
 4. The method of claim 3, wherein the oxygen concentrator further comprises an oxygen sensor coupled to the accumulation chamber, wherein the oxygen sensor is capable of detecting oxygen in a gas during use, wherein the method further comprises assessing a relative concentration of oxygen in the accumulation chamber using the oxygen sensor.
 5. The method of claim 3, wherein the oxygen concentrator further comprises: an airway delivery device coupled to the accumulation chamber and positionable on the face of a user; and a pressure sensor coupled to the airway delivery device; wherein the pressure sensor is operable to detect a change in pressure at the airway delivery device; wherein the method further comprises: directing the oxygen enriched gas from the accumulation chamber to the airway delivery device in response to detecting a drop in pressure at the airway delivery device.
 6. The method of claim 5, further comprising producing an alarm or other signal in response to an absence of a drop in pressure for a predetermined amount of time.
 7. The method of claim 5, further comprising: assessing a change in pressure during an inhalation of the user; assessing a pressure change rate based on the detected user inhalation; and if the pressure change rate indicates the user is in an active state, implement a first mode of providing oxygen enriched gas to the user; and if the pressure change rate indicates the oxygen concentrator user is in a sedentary state, implement a second mode of delivery of oxygen enriched gas to the user, the second mode of delivery being different from the first mode of delivery.
 8. The method of claim 1, wherein directing the oxygen enriched gas to the user comprises providing a pulse of the oxygen enriched gas to an airway delivery device coupled to the user's face.
 9. The method of claim 1, wherein directing the oxygen enriched gas to the user comprises delivering a bolus of oxygen enriched gas to a user in two or more pulses; wherein a volume of the bolus is approximately an amount of oxygen determined to be delivered to the user during a single breath.
 10. The method of claim 1, wherein the separation material comprises a zeolite. 